Deck system

ABSTRACT

A system of mounting an array of decking material including a sub frame and a support grid including a plurality of boards mounted on top of the sub frame. A plurality of pavers may be laid on top of the grid system, with each paver held to the grid system by a plurality of clips. Each clip attached to the support grid and engaging a groove formed along an outer edge of the paver, the clips not extending to or above a top surface of the pavers.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Application Ser. No. 61/256,808, the disclosure of which is incorporated herein by reference in it entirety.

BACKGROUND

The present disclosure relates generally to a new approach to the construction and layout of decking and structural supports for decking. The elements of the present disclosure are presented in three distinct pieces: the grid for supporting and securing the decking materials; clips for securing the decking materials to the grid; and the decking materials or pavers themselves which are secured to the support grid with the clips. Improvements to the conventional approaches of supporting and securing decking are provided by one or more of the disclosed elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawing figures, which are incorporated in and constitute a part of the description, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the figures is as follows:

FIG. 1 is a perspective view of a partially assembled deck system according to the present disclosure.

FIG. 2 is a perspective view of a sub frame of the deck system of FIG. 1.

FIG. 3 is a perspective view of a support grid of the deck system of FIG. 1.

FIG. 4 is a perspective view of first paver to be installed during construction of the deck system of FIG. 1, with the sub frame and support grid removed for clarity.

FIG. 5 is a top perspective view of a first pair of pavers to be installed during construction of the deck system of FIG. 1, with the sub frame and support grid removed for clarity.

FIG. 6 is a bottom perspective view of the pair of pavers of FIG. 5.

FIG. 7 is a perspective view of an assembly clip according to the present disclosure for use with the deck system of FIG. 1.

FIG. 8 is an end view of the clip of FIG. 7.

FIG. 9 is a top view of the clip of FIG. 7.

FIG. 10 is a perspective view of a replacement clip according to the present disclosure for use with the deck system of FIG. 1.

FIG. 11 is an end view of the clip of FIG. 10.

FIG. 12 is a top view of the clip of FIG. 10.

FIG. 13 is a perspective view of a decking paver according to the present disclosure for use with the decking system of FIG. 1.

FIG. 14 is a bottom view of the decking paver of FIG. 13.

FIG. 15 is a first side view of the decking paver of FIG. 13, with recesses in the lower face of the paver shown in hidden lines.

FIG. 16 is a second side view of the decking paver of FIG. 13.

FIG. 17 is a cross-sectional view of a portion of the decking paver of FIG. 14 marked with Line B-B.

FIG. 18 is a second cross-sectional view of portion of the decking paver of FIG. 14 marked with Line A-A.

FIG. 19 is a perspective view of a first alternative embodiment of a decking paver according to the present disclosure.

FIG. 20 is a perspective view of a second alternative embodiment of a decking paver according to the present disclosure.

FIG. 21 is a top perspective view of a combination of embodiments of decking pavers to for a portion of a deck surface in the decking system of FIG. 1.

FIG. 22 is a bottom perspective view of a combination of embodiments of decking pavers to for a portion of a deck surface in the decking system of FIG. 1.

FIG. 23 is a side cross-sectional view of a decking system according to the present disclosure assembled directly on the ground.

FIG. 24 is a perspective view of an alternative embodiment of a decking system according to the present disclosure used to install decking pavers on an existing sub frame.

DETAILED DESCRIPTION

The support grid may include a plurality of transverse boards mounted on top of a base or sub frame structure for securing and supporting the decking materials or pavers according the present disclosure. The decking material may be placed on top of the grid system and secured with one or more paver clips. The process for assembling a support grid and sub frame for a decking system according to the present disclosure is illustrated in FIGS. 1 to 3.

FIG. 1 illustrates a decking system 100 according to the present disclosure with a sub frame 102 with a plurality of joints 104 extending generally parallel to each other and spaced apart from each other. The size of the joints and the spacing of the joists are preferably determined using standard formulas based on the weight that the deck will be designed to support and the span between supports for the sub frame. FIG. 2 illustrates an exemplary positioning and assembly of joists 104 into sub frame 102.

FIG. 3 illustrates the assembly of a support grid 106 transversely on sub frame 102. Support grid 106 may be comprised of a plurality of stringers 108 as illustrated in FIG. 3. These stringers may be smaller that the joists and are preferably laid on a side to provide a wider upper surface for receiving the decking material and clips holding the material to the support grid. The stringers may be attached to the sub frame using conventional fasteners or fastening methods in compliance with local building codes or standards.

Both the sub frame structure and the support grid may be preferably comprised of treated wood lumber, with the assumption that the deck may be exposed to environmental conditions or to materials or surfaces including some degree of entrained moisture. Other suitable materials may be used for the support grid and sub frame structures that provide similar load carrying capacity and environmental or moisture resistance. The support grid may be placed on the sub frame to support the pavers in a variety of patterns as shown in the figures below. The sub frame design beneath and supporting the support grid would be dependent on load requirements. The grid system may be secured to the sub frame in a conventional fashion such being secured by galvanized nails or deck screws.

The composite paver pattern determines the center to center grid spacing to ensure the paver edge is supported. In the present disclosure an exemplary installation pattern and support grid configuration is shown. This exemplary installation and pattern is not intended to be limiting to the scope of the overall disclosure and it is anticipated that different arrangements of sub frames, support grids and decking materials may be used within the scope of the present disclosure.

FIG. 4 illustrates the placement and securement of a first decking paver 110 to stringers 108 of support grid 106. To secure paver 110, the paver is positioned in the desired location on the support grid based on the pattern of pavers desired. Once the paver is positioned, a plurality of securing clips 112 may be placed about the paver engaging a groove or slot 114 formed in a perimeter edge 116 of paver 110. Preferably at least two clips 112 are positioned to engage each side of paver 110. Once the clips are positioned, a fastener such as a screw may be driven through an opening 118 of clip 112 into one of the stringers 108 of the support grid 106. Clips 112 and paver 110 are shown and described more particularly below.

FIG. 5 illustrates the positioning and securement of a second paver 120 adjacent the first paver 110 positioned and secured to the support grid. Second paver 120 is placed next to a side of first paver 110 and slide toward first paver 110 so that perimeter groove 114 of second paver 120 engages clips 112 along that side of first paver 110. When second paver 120 is aligned as desired with respect to first paver 110, additional clips 112 may be positioned about the other unsecured sides of second paver 120 engaging groove 114 on those sides and fastened to support grid 106 to secure second paver 120 to decking system 100.

FIG. 6 illustrates a lower surface of first and second pavers 110 and 120 with clips 112 positioned about the respective sides of the pavers. Each paver may preferably include a recess 122 along a lower edge to permit clips 112 to slide between the paver and the support grid without elevating the paver from contact with the support grid.

Referring now to FIGS. 7 to 9, clip 112 may include a base portion 124, a web portion 126 extending upward from base 124 and a t-shaped top 128 with sides 132 sized to engage groove 114 of paver 110. Base 124 may include one or more fastener openings 118 on each side of web 126. Preferably, openings 118 are spaced apart from web 126 so that fasteners may be driven vertically without interfering with top 128. A notch or other recess may be providing in top 128 to permit the head of a fastener to pass top 128 while being driven or screwed into support grid 106 without impacting or damaging top 128. A single fastener in a clip 112 should be sufficient to secure the clip and adjacent pavers to the support grid but two openings 118 are preferably provided so that the clip may be secured regardless of orientation.

Clip 112 includes a top 128 configured to secure a paver during initial installation. However, it is possible that paver may be damaged post-installation and may need to be replaced for structural, safety or esthetic reasons. To remove and replace a paver without disturbing the adjacent pavers, a second replacement clip 212, illustrated in FIGS. 10 to 12 may be used.

Once decking system 100 is fully installed, a single paver may be removed for replacement by first cutting into the paver from above. Since each paver is secured with one or more (preferably two or more) clips along all sides, the paver needs to be cut in the middle so that pieces of the paver may be removed from engagement with the clips. Once the paver has been removed, the clips 112 about the space where the paver was positioned may also be removed. Before a new paver is positioned into the space, clips 112 are preferably replaced with clips 212.

Clips 212 may include base 124 and web 126 with a different top 228. While top 228 is also configured and sized to engage groove 114 of paver 110, it is also configured to be slightly undercut along area 230 to permit paver 110 to be pushed down vertically into the space left by the removed tile. Undercut 230 removes some material from top 228 and permits deflection of a side 232 of top 228 when pressed downward by the replacement paver. Once the paver is pressed deep enough to engage the support grid at the bottom of the space, side 232 of top 228 will preferably enter groove 114 and return to its generally t-shape as shown in the FIGS. This engagement of groove 114 of the replacement paver 110 by the clips 212 about the space will then secure the replacement paver into the space and return the decking system to its original condition.

An upper surface 234 of each side 232 of top 228 may be preferably sloped to aid in the insertion of a paver from above into a space left by the removal of a broken or damaged paver. Such a sloped upper surface may aid in centering the replacement paver between the clips 212, may allow sides 232 to be more tapered to make deflection of the sides easier, as well as providing other advantages not otherwise listed herein.

Referring now to FIGS. 13 to 18, a paver 210 for use with decking system 100 is illustrated with an upper surface 150, a lower surface 152 and edges 154 including groove 114 extending about a perimeter of the edges. Paver 210 may also include recess 122. Upper surface 150 may be textured in a variety of patterns or finishes to mimic wood, stone, slate, or any of a multitude of other finishes. Preferably paver 210 is made of a composite material that is capable of being formed or machined into the shapes described herein while having sufficient strength to serve as a decking material and engage the clips described herein to serve as part of decking system 100. It is not intended to limit the material from which the pavers may be made provided the pavers have the desired strength, appearance and weight characteristics.

An upper portion 156 of edges 154, adjacent upper surface 150, may be uneven to mimic a particular decking material, as shown, or may be more precisely machined or formed to fit with the adjacent pavers in decking system 100. A lower portion 158 of edges 154, between groove 114 and lower surface 152, may be preferably inset from upper portion 156. This insetting of lower portion 158 may permit upper portion 156 of adjacent pavers 210 to be laid closer to each other and reduce visibility of clips 112/212 or support grid 106 between the pavers. If a wider spacing between adjacent pavers is desired for visual or performance reasons (such as but not limited to enhancing drainage through the deck) the upper and lower portions may be more inline with each other vertically. Recess 122 may be provided in lower surface 152.

On lower surface 152, a plurality of recesses 160 may be formed to remove material from paver 210 and possibly reduce the cost and weight of each paver. Care must be taken in the design and configuration of such recesses 160 to ensure that sufficient support is maintained based on the expected load to be carried by the paver to avoid excessive deflection. Also on lower surface 152 may be provided a plurality of channels 162 sized and positioned to receive tubing for in-floor heating systems. These channels 162 permit the inclusion of a heated floor within decking system 100 without raising the overall height of the system. With proper configuration and spacing of channels 162 under paver 210, tubing may be run continuously beneath pavers 210 in a decking system 100 due to the alignment of the channels in adjacent tiles.

Channels 162 may also serve the dual purpose of removing material from paver 210 in a similar fashion to recesses 160. Channels 162 and recesses 160 may be included together or separately in paver 210. Alternatively, paver 110 may be made with a smooth continuous bottom as shown in FIG. 6.

FIGS. 19 and 20 illustrate two additional embodiments of pavers 310 and 410, respectively. These pavers differ from paver 210 primarily in size. These pavers may be configured to correspond in size to pavers 110 and 210 to permit various patterns to be made in the pavers in decking system 100. These pavers 310 and 410 may also include one or both of recesses 160 and channels 162 which are preferably configured to cooperate with channels 162 in other pavers to permit in-floor heat tubing to pass continuously underneath pavers of different sizes.

FIGS. 21 and 22 illustrate how pavers of various sizes may be combined to define a particular pattern on top while maintaining the continuous tubing channels 162 underneath.

FIG. 23 illustrates how pavers according to the present disclosure, such as pavers 510 shown, may be used with clips according to the present disclosure, such as clips 212 shown, to secure a decking system 200 on top of a compacted soil or a sub base 202 such as limestone or similar base material. Note that pavers 510 illustrated have upper portions 156 and lower portions 158 that are vertically aligned to permit grouting between pavers with grout 204 to secure the decking system 200 and prevent water infiltration through the deck and possible damaging sub base 202.

The decking systems above have assumed that there are no limitations to the height of the top of the decking pavers with respect to an existing sub frame or similar support structure. In some installations, it may be desirable to install decking pavers such as 110, 120, 310, 410 and 510, or similar decking materials within the scope of the present disclosure, onto an existing structure. There may be adjacent structures or features, such as but not limited to doors, windows, railings, etc., that are adjacent to where the deck is to be laid that may require a specific height above the existing structure or sub frame. FIG. 24 illustrates a retrofit arrangement or original installation arrangement 300 for such a height limited situation. Instead of having the support grid positioned on top and fastened to the frame 102, a support grid 306 is assembled between joists 104 from a plurality of grid elements 308. To aid in the positioning and fastening of grid elements 308 to joists 104, a cleat 312 may be fastened along each side of each joist set below a top of each joist by the height of grid elements 308. When grid elements 308 are placed on the cleats, the top of each grid element is preferably flush with the top of the joists.

A typical support grid may be made of 2×4 dimensional lumber, which is a nominal 1.5 inches thick. Arrangement 300 thus would typically allow for a lowering of approximately 1.5 inches of the overall height of the finished deck surface once the pavers are installed on the grid system as described above.

Prior Disclosure Material

The clip is used to secure the paver to the grid system. The clip may be made from a plastic material which is durable and resistant to UV rays. Other materials may be used to form the clips provided that these materials have suitable qualities to perform as described below. This clip is preferably “I” shaped with the top portion of the clip slightly smaller in width from the bottom. This allows better access to fasten the clip to the support grid. The top of the clip may be beveled to allow replacement of a composite paver from a deck after installation without requiring all or a significant portion of the installed deck to be disassembled. Alternatively, a second embodiment of a clip may be used to facilitate replacement of pavers from a completed deck. This replacement of a single paver may be done by removing damaged composite paver and snapping replacement paver downward with even pressure.

Two holes may be provided on a bottom of the clip to permit the paver clip to serve as a universal clip, with only one fastener needed per clip. The clip may be inserted into the groove of the paver and fastened to the grid system with one fastener. The top of the clip may have a relief to allow clearance for a screw bit. The adjoining paver will then be slid into the secured paver clip and the process will be repeated.

Decking Materials and Composite Pavers

The term paver is used generically to describe any of a number of alternatives that might be suitable for use as decking material in conjunction with the present disclosure. This composite paver may be manufactured from recycled material.

Benefits

-   -   Less weight than a concrete paver     -   Easier handling     -   Slip resistant surface     -   Colored through paver     -   Textured surface to resemble slate     -   Can be cut using normal wood working tools (skill saw, miter         saw, etc.)     -   With plans to be available in various colors, textures,         thicknesses, sizes and shapes     -   Different thicknesses can be manufactured for certain         applications

The paver bottom and sides may be preferably smooth, while the top side of the paver may have a textured surface which can come in different textures and colors. Different size pavers can also be arranged to create patterns. The paver may include a groove around the side periphery with a relief around the bottom periphery. The side groove may be configured to engage the clip which will secure the composite paver to the grid. The bottom relief is used as clearance for the base of the clip and allows the composite paver to sit flat onto grid.

The embodiments of the inventions disclosed herein have been discussed for the purpose of familiarizing the reader with novel aspects of the present invention.

Although preferred embodiments have been shown and described, many changes, modifications, and substitutions may be made by one having skill in the art without unnecessarily departing from the spirit and scope of the present invention. Having described preferred aspects and embodiments of the present invention, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which may be appended hereto. 

1. A system of mounting an array of decking material comprising: a sub frame; a support grid including a plurality of boards mounted on top of the sub frame; a plurality of pavers laid on top of the support grid; each paver held to the support grid by a plurality of clips, each clip attached to one of the support grid boards and engaging a groove formed along an outer edge of the paver, the clips not extending to or above a top surface of the pavers.
 2. The system of claim 1, further comprising each of the clips including a base positioned on the support grid, a web extending upward from the base to a t-shaped top including sides extending outward into the grooves along the pavers.
 3. The system of claim 2, further comprising each of the pavers including sides and a lower surface, with a peripheral recess in the lower surface along a lower edge of each side with the recess sized to receive the base of the clip so that the lower surface of the paver rests on the support grid.
 4. The system of claim 2, further comprising at least one of the pavers held in place by a plurality of clips including an undercut beneath at least one of the sides of the top, with the side being deflectable to permit a paver to be inserted into the system vertically from above.
 5. The system of claim 1, further comprising at least one of the pavers including a lower surface, the lower surface including a plurality of channels sized to receive tubing for an in-floor heating system.
 6. The system of claim 1, further comprising at least one of the pavers including a lower surface, the lower surface including at least one recess to remove material ad weight from the paver while permitting the paver to rest on the support grid.
 7. The system of claim 1, further comprising each of the pavers including sides, an upper surface and a lower surface, the groove being formed in the sides of the paver between the upper and lower surfaces, a lower portion of the side between the groove and the lower surface being inset with respect to an upper portion of the side between the groove and the upper surface, the inset of the lower portions sized to permit the positioning of the clips between adjacent pavers with the upper portions of the adjacent pavers closely positioned with respect to each other.
 8. A system of mounting an array of decking material comprising: a compacted sub base; a plurality of pavers laid on top of the sub base; each paver held to the sub base by a plurality of clips, each clip attached to the sub base and engaging a groove formed along an outer edge of the paver, the clips not extending to or above a top surface of the pavers.
 9. The system of claim 8, further comprising each of the clips including a base positioned on the sub base, a web extending upward from the base to a t-shaped top including sides extending outward into the grooves along the pavers.
 10. The system of claim 9, further comprising each of the pavers including sides and a lower surface, with a peripheral recess in the lower surface along a lower edge of each side with the recess sized to receive the base of the clip so that the lower surface of the paver rests on the sub base.
 11. The system of claim 8, further comprising at least one of the pavers including a lower surface, the lower surface including a plurality of channels sized to receive tubing for an in-floor heating system.
 12. A method of installing a decking system, the system comprising: providing a sub frame; positioned a support grid on top of the sub frame; providing first and second pavers, each paver including sides and a lower surface, the sides of each paver including a peripheral groove; positioning the first paver on the support grid in a desired location; providing a plurality of clips, each clip having a base, an upward extending web and a t-shaped top; positioning at least one clip along a first side of the first paver with the base beneath the paver and on top of the support grid, and one side of the top engaging the groove along the side of the paver; securing the clip to the support grid; positioning at least one clip along the remaining sides of the first paver and securing the clips to the support grid to hold the first paver to the support grid; positioning the second paver adjacent the first paver with the groove of the side of the second paver adjacent the first paver engaging the clips holding the first paver to the support grid; positioning at least one clip along the remaining sides of the second paver and securing the clips to the support frame to hold the second paver to the support grid adjacent to the first paver. 